Terminal construction for electrical switches or the like



March 5, 1968 M. F. BEDOCS 3,372,365

ES OR THE LIKE TERMINAL CONSTRUCTION FOR ELECTRICAL SWITCH I N VE N T 02 Michael Ffiedvcs JZMwLm CZiZ'ys United States Patent M 3,372,365 TERMINAL CQNSTRUCTION FOR ELECTRICAL SWETCHES OR THE LIKE Michael F. Bedocs, Wilmette, Ili., assignor to Indak Manufacturing Corp., Northhrook, IiL, a corporation of Illinois Filed Dec. 23, 1965, Ser. No. 515,890 4 Claims. (Cl. 339-186) ABSTRACT OF THE DISCLOSURE An insulating member, a plurality of terminal prongs projecting beyond said member, a connector having receptacle openings for receiving said prongs, said openings having receptacle contacts therein for engaging said prongs, said connector having an extra receptacle opening therein, and a locating peg on said insulating member and receivable in said extra opening when said connector is properly oriented, each of said receptacle openings having a main portion for receiving one of the prongs and a narrower side portion for receiving the receptacle contact, said peg being receivable in the narrower side portion of the extra opening.

This invention relates to electrical switches or other devices to which electrical leads may be connected.

One object of the present invention is to provide an electrical switch or the like having a new and improved terminal construction whereby electrical leads may be connected to the switch.

A further object is to provide a terminal construction in which a plurality of terminals are arranged in a new and improved manner so as to be adapted to receive a connector or receptacle to which electrical leads are attached.

Another object is to provide such a new and improved terminal construction in which the terminals are connected to contact rivets or the like mounted in a circular or other pattern on an insulating board, and in which the terminals are formed with prongs projecting in a single row from one edge of the terminal board.

It is a further object to provide a new and improved terminal construction of the foregoing character in which the terminals interlock with the insulating board to maintain the prongs in fixed positions.

Another object is to provide such a new and improved terminal construction in which the terminals and the insulating board are formed with interlocking slots.

A further object is to provide a new and improved switch or the like in which the prongs are adapted to receive a connector or receptacle, and in which the insulating board is formed with a locating peg or prong to engage the connector and prevent the connector from being mounted backwards on the switch.

It is a further object to provide such a new and improved switch in which the locating peg is adapted to be received in one of a series of regularly spaced openings in the connector, the other openings being provided with clips or the like for engaging the terminal prongs on the switch.

Another object is to provide a new and improved terminal and. connector construction for switches or the like, having the advantages of sturdiness in construction and convenience in use as Well as being extremely low in cost.

Further objects and advantages of the present invention will appear from the following description, taken with the accompanying drawings, in which:

FIGS. 1, 2 and 3 are front, side and rear elevational views of a switch, together with its connector, to be de- 3,372,365 Patented Mar. 5, 1968 scribed as an illustrative embodiment of the present invention, the connector being shown in a detached position for clarity of illustration.

FIG. 4 is a bottom plan view of the switch, taken generally as indicated by the line 4-4 in FIG. 1.

FIG. 5 is a top plan view of the connector, taken generally as indicated by the line 55 in FIG. 1.

FIG. 6 is a fragmentary exploded perspective view showing one of the terminals for the switch, together with the slotted edge of the terminal board, with which the terminals are adapted to interlock.

FIG. 7 is a rear view of the switch with the terminal board removed to reveal the carriage and the contactors, the view being taken generally along the line 77 in FIG. 2.

FIG. 8 is a front view of the detached terminal board, revealing the contacts which are normally concealed with in the switch, the view being taken generally along the line 88' in FIG. 2.

FIG. 9 is a fragmentary somewhat diagrammatic view, taken generally along the line 9-9 in FIG. 3.

As already indicated, the drawings illustrate an electrical switch 10, to be described as an example of an electrical device having a terminal and connector construction in accordance with the present invention. The illustrated switch 10 happens to be of the rotary type, having a casing 12 in which a carriage or rotor 14 is rotatably mounted. The illustrated carriage 14 has a front shaft portion 16 which projects forwardly through a sleeve or bearing 18 formed on the front wall 20 of the casing 12. An operating lever 22 is riveted or otherwise secured to the shaft 16.

The illustrated switch 10 happens to have three contactors 24, 25 and 26 which are mounted on the rear side of the carriage 14. The contactors are engageable with a series of contacts 31, 32, 33, 34 and 35 which are mounted on an insulating support, preferably in the form of a terminal board 36. The contacts 31-35 are preferably in the form of contact rivets extending through the insulating board 36. In the illustrated switch, the contacts 31-35 are spaced at irregular intervals in a generally circular pattern.

As shown, the contact rivet 31 is connected to a contact ring 38 which is mounted against the insulating board 36, within the circular pattern formed by the rivets 31-35. The rivet 31 engages the outwardly projecting arm 40 which is formed on the contact ring 38. Each of the contactors 24-26 engages the contact ring 38 in all positions of the carriage 14. To engage the contact ring 38, each of the contactors 24-26 is formed with a rearwardly projecting contact point or boss 42. The contactors 24-26 are biased rearwardly by springs 44 which are compressed between the carriage 14 and the contactors.

In the illustrated construction, the contact rivet 32 is connected to a contact segment 46 which is secured between the contact rivet 32 and the insulating board 36. The contact segment 46 effectively extends the arcuate length of the contact point 32. It will be seen that the opposite ends of the contact segment 46 are formed with forwardly projecting contact points or bosses 48 and 49, on opposite sides of the contact rivet 32.

In the illustrated switch, the insulating terminal board 36 is formed with a plurality of forwardly extending insulating bosses or projections 51, 52, 53, 54 and 55, which are preferably in the form of semiperforations, pressed forwardly from the insulating board 36. It will be seen that the insulating boss 51 is between the contact rivet 33 and contact boss 48. The insulating boss 52 is between the contact rivets 33 and 34. The insulating bosses 53 and 54 are disposed between the contact rivets 34 and 35. As shown, the insulating bosses 51-54 are circular in shape, the boss 52 being smaller than the bosses 51, 53 and 54.

The illustrated insulating boss 55 is oval or elongated in shape and is disposed between the contact rivets 31 and 35.

The switch is preferably provided with a plurality of terminals 61, 62, 63, 64 and 65 which are secured to the rear side of the insulating board 36 by means of the contact rivets 31-35, respectively. As shown to best advantage in FIG. 6, each of the terminals 61-65 is generally in the form of a metal bar or strip 66 having a lug or bracket portion 68 which is secured to the corresponding contact rivet. The lug 68 is bent at right angles to the bar 66 and is formed with an opening 70 to receive the rivet. The bar 66 extends edgewise along the rear side of the insulating board 36 and is spaced slightly therefrom, to avoid any contact with any of the other terminals.

The terminals 61-65 are formed with respective prongs 71-75. Preferably, all of the prongs 71-75 are parallel to one another and are arranged along a single row. The prongs 71-75 preferably project in one direction from one edge portion 76 of the insulating board 36. The edge portion 76 preferably projects beyond the outline of the casing 12. The terminal board 36 may be secured to the casing 12 by means of tabs 78 which project rearwardly therefrom and are bent behind the terminal board. One of the tabs 78 extends through an opening 80 which is formed in the overhanging edge portion 76 of the terminal board. The other tabs 78 may extend through slots or notches 82 formed in the edges of the insulating board 36. The carriage 14 may be formed with a rear shaft portion 84 which is rotatably received in an opening 86 formed in the insulating board 36.

The terminals 61-65 are preferably constructed and arranged so as to interlock with the insulating board 36, so that the terminals will be securely retained in fixed positions. Thus, the insulating board 36 is preferably formed with slots or notches 88, adapted to interlock with slots or notches 90 formed in the terminals 61-65. The slots 88 are formed in the over-hanging edge portion 76 of the insulating board 36. As shown to best advantage in FIG. 6, each of the terminals 61-65 is formed with a portion 92 which is adapted to be received in the corresponding slot 88. The portion 92 extends forwardly from the bar portion 66 of the terminal. It will be seen that the slot 90 is formed in the forwardly projecting portion 92 of the terminal. In front of the slot 90, each terminal has an ear or lug 94 which projects in front of the insulating board 36. The ear 94 is hooked in front of the board 36 to prevent rearward movement of the terminal and the corresponding prong. The forwardly projecting portion 92 of the terminal is at the base of the corresponding prong.

It will be recognized that the interlocking engagement between the slots 88 in the insulating board 36 and the slots 90 in the terminals 61-65 prevents any rotation of the terminals about the corresponding contact rivets 31- 35. Moreover, the ears 94 on the terminals prevent the terminals from being bent rearwardly away from the insulating board 36. The bar portions 66 of the terminals prevent any forward movement of the terminals. Thus, the terminals 61-65 and the corresponding prongs 71-75 are rigidly fixed in position relative to the insulating board 36.

It is preferred to provide a connector or receptacle 96 which is adapted to be connected to the prongs 71-75. The illustrated connector 96 comprises an insulating body 98 which is formed with a series of regularly spaced openings 101-106. The openings 101-105 are adapted to receive the corresponding prongs 71-75. To engage the prongs 71-75, clips or other similar members 111-115 are mounted in the openings 101-105.

Each of the openings 101-106 is formed with a main portion 116 of full width, adapted to receive the corresponding prong. Each of the openings 101-106 is also formed with a side portion 118 of ess width, adapted to receive the corresponding clip. The side portion 118 opens into one side of the main portion 116.

Electrical leads 121-125 are connected to the corresponding clips 111-115. The leads 121-125 are employed to connect the switch or other device into the desired electrical circuit.

While the openings 101-105 in the connector 98 are employed to hold the clips 111-115, the opening 106 is left empty. Otherwise, the opening 106 is the same as the other openings 101-105. The opening 106 is preferably employed to receive a locating peg or prong 126 which is formed or mounted on the insulating board 36. In this case, the locating peg 126 is formed integrally with the insulating board 36 and is disposed between the prongs 71-74. The locating peg 126 is adapted to be received in the side portion 118 of the opening 106. In this case, the peg 126 also extends to some extent into the main portion 116 of the opening 106.

It will be seen that the locating peg 126 is closer to the prong 71 than to the other adjacent prong 74. Thus, the peg 126 is adapted to prevent the connector 96 from being mounted backwards on the prongs 71-75. After an attempt is made to mount the connector backwards, the peg 126 comes into engagement with the web portion 128 of the body 98 between the openings 101 and 106. Thus, the locating peg 126 prevents the mounting of the connector 96 on the switch 10 in the wrong position. The arrangement of the locating peg 126 has the particular advantage that a standard connector may be employed, without any special provision for receiving the locating peg. Five of the six openings in the connector are employed to receive terminal clips, in the normal manner, while the sixth opening is employed to receive the locating peg 126. It will be noted that the peg 126 is received in the side portion of the sixth opening, normally employed to receive a terminal clip.

The lead 121 may be connected to a battery or other source of power. Thus, the battery voltage is continuously supplied to the terminal 61, the contact 31 and the contact ring 38. The other contacts 32-35 may be connected to circuits which are to be supplied with the battery voltage in various positions of the switch.

The switch is illustrated in its Otf position, in which the contactor 26 engages the battery contact 31. The contactor 24 engages the insulating boss 51, while the contactor 25 engages the insulating bosses 53-54. When the carriage is rotated counterclockwise as seen in FIG. 7, the contactor 24 comes into engagement with the contact segment 46. Such engagement is maintained for a considerable angular interval, because of the provision of the contact point 32 and the contact bosses 48 and 49. During this angular interval, the contactor 25 comes into engagement with the contact rivet 34. Then, the contactor 26 moves into engagement with the contact rivet 35. After still further movement of the carriage 14, the contactor 25 engages the contact rivet 33, and then moves out of engagement with the rivet 34. Similarly, the contactor 26 moves out of engagement with the contact 35, while the contactor 24 moves out of engagement with the contact segment 46. It will be understood that the specific construction and arrangement of the switch contacts and contactors may be varied.

By virtue of the interlocking engagement between the slots 88 and 90, the terminals 61-65 are rigidly secured to the insulating terminal board 36. Thus, the connector 96 may be engaged with and disengaged from the prongs 17-75 Without disturbing the positions of the prongs. The interlocking slots 88 and prevent rotation of the terminals 61-65 about the contact rivets 31-35, while also preventing the terminals from being bent rearwardly away from the insulating board 36.

The oddly positioned locating peg 126 prevents the connector 96 from being mounted backwards on the prongs 71-75. When the connector 96 is correctly positioned, the peg 126 enters the side portion 118 of the opening 106. When the connector 96 is incorrectly positioned, the peg engages the web portion 128 of the body 98 between the openings 101 and 106. The locating action of the peg 126 is positive, yet is achieved at an extremely low cost.

In the illustrated switch, at least one detent opening or recess 140 is formed in the front of the casing 12 and is adapted to be engaged by a detent ball or other member 142, mounted on the carriage 14. A coil spring 144 is provided to press the ball 142 against the front of the casing 12 so that the ball will be detained in the opening 140 when the carriage is rotated so as to bring the ball opposite the opening.

The operating lever 22 of the illustrated switch is securely mounted in a slot or groove 146 which is formed in the front end of the shaft 16. As already indicated, a rivet or other fastener 148 is employed to fasten the lever 22 to the shaft 16 so that the carriage 14 will rotate with the lever. It will be seen that the lever 22 has a flat member 150 at its inner end which is fitted into the slot 146. It is preferred to form the fiat member 150 with one or more portions 152 which project outwardly beyond the shaft 16. As shown in FIG. 1, the outwardly projecting portions 152 are opposite the end of the sleeve or bearing 18. Thus, the outwardly projecting portions 152 retain the shaft 16 in the sleeve 18 against rearward movement.

During the assembly of the switch, the detent ball 142 and its spring 144 are mounted on the carriage 14, and the carriage is then mounted within the casing 12. The shaft 16 is inserted through the sleeve 18, and the lever 22 is then riveted to the front end of the shaft. The outwardly projecting portions 152 of the lever 22 prevent rearward movement of the shaft 16, so that the detent ball 142 and its spring 144 will be retained in their normal positions while the rest of the switch is being assembled. When the switch is fully assembled, the projecting portions 152 of the lever are spaced slightly in front of the sleeve 18 so that they do not rub or bind on the sleeve. The provision of the outwardly projecting portions 152 on the lever 22 greatly facilitates the assembly of the switch.

Various other modifications, alternative constructions and equivalents may be employed without departing from the true spirit and scope of the invention, as exemplified in the foregoing description and defined in the following claims.

I claim:

1. In an electrical device,

the combination comprising an insulating board,

a plurality of terminal bars extending along one side of said board and terminating in prongs projecting beyond one edge of said board,

means for securing said terminal bars to said board,

a connector having a plurality of receptacle openings for receiving said prongs,

said openings having receptacle contacts therein for engaging said prongs,

said connector having an extra receptacle opening therein,

and a locating peg on said board and receivable in said extra opening when said connector is properly oriented relative to said prongs,

said connector having a body portion engageable with said peg to prevent full engagement of said connector with said prongs when said connector is reversely oriented relative to said prongs, each of said receptacle openings in said connector being formed with a main portion for receiving the corresponding prong and a narrower side portion adapted to receive the corresponding receptacle contact,

said peg being receivable in said narrower side portion of said extra opening when said connector is properly oriented relative to said prongs.

2. A combination according to claim 1,

in which said peg is disposed between two of said prongs and is off-center therebetween.

3. In an electrical device,

the combination comprising an insulating member,

a plurality of terminal prongs disposed on said memher and projecting beyond one edge thereof, 1

means for securing said prongs to said member,

a connector having a plurality of receptacle openings for receiving said prongs,

said openings having receptacle contacts therein for engaging said prongs,

said connector having an extra receptacle opening therein,

and a locating peg on said insulating member and receivable in said extra opening when said connector is properly oriented relative to said prongs,

said connector having a body portion engageable with said peg to prevent full engagement of said connector with said prongs when the connector is reversely oriented relative to said prongs,

each of said receptacle openings in said connector being formed with a main portion for receiving the corresponding prong and a narrower side portion for receiving the corresponding receptacle contact,

said peg being receivable in said narrower side portion of said extra opening when said connector is properly oriented relative to said prongs.

4. A combination according to claim 3,

in which said peg is disposed between two of said prongs and is off-center therebetween.

References Cited UNITED STATES PATENTS 2,143,401 1/1939 Arrin -504 2,796,497 6/1947 Barden 200168 2,962,692 11/1960 White 399- X 3,158,418 1/1964 Rush 339-17 3,181,108 4/1965 Hoy et al. 339-176 X FOREIGN PATENTS 1,023,038 3/1966 Great Britain. 1,081,523 5/1960 Germany.

MARVIN A. CHAMPION, Primary Examiner.

60 I. R. MOSES, Assistant Examiner. 

